Horizontal production separator with helical emulsion circulation coils

ABSTRACT

A separator for separating wellbore emulsions into liquid and gaseous components has helical emulsion preheat coils encircling a single-cylinder, dual chamber firetube disposed inside a horizontal separator vessel. In use, emulsion enters the preheat coils before entering the separator vessel. The flow of emulsion through the helical coils promotes initial separation of the emulsion by means of heat transfer and centrifugal flow. Resultant centripetal force separates lighter gaseous and liquid particles toward the inside of the helical coils, while heavier emulsion fractions condense toward the outside of the helical coils. The use of helical preheat coils and a single-cylinder, dual-chamber firetube eliminate or minimize abrupt changes in emulsion flow direction that are characteristic of prior art separators, resulting in reduced wear in both the coils and the firetube.

FIELD

The present disclosure relates in general to apparatus for separatingfluids from oil and gas wells into liquid and gaseous components, andrelates in particular to horizontally-oriented production separators forinitial heating and centrifugal separation of emulsion from an oil orgas well prior to entering a vessel for gravity and pressure separation.

BACKGROUND

Oil and gas wells typically produce an emulsion comprising, in varyingproportions, hydrocarbon liquids (e.g., crude oil), hydrocarbon gases(natural gas), and water. Production separators, which may behorizontally, vertically, or spherically configured, are commonly usedto heat the emulsion in order separate it into liquid, gaseous, andwater fractions.

One commonly-used production separator circulates emulsion through asystem of U-shaped piping loops disposed inside a horizontally-orientedpressure vessel. Each piping loop includes a pair of straight parallelpipe runs connected at one end by a short-radius 180-degree elbow, withthe other ends of the straight runs (i.e., inlet and outlet ends) beingconnected to a flanged vessel head mounted to one end of the pressurevessel (typically by bolting), and with the elbow ends of all pipingloops projecting from the vessel head into the interior of the vessel.The vessel head is fitted with suitable piping connections for receivinga flow of emulsion from a wellhead and flowing the emulsion through thepiping loop system inside the vessel. A U-shaped horizontal firetube isprovided inside the vessel below the piping loop system to transfer heatto the piping and the emulsion flowing therethrough. This particulartype of separator is sometimes referred to as a “180-10-pass” design(denoting 10 piping loops with 180° elbows).

This type of prior art separator (which is illustrated in FIG. 1 herein)has a number of practical and operational drawbacks. For example, it isprone to high internal pipe wear, particularly at the short-radius 180°elbows. Another drawback is that the circulating emulsion tends to befurther comingled due to the turbulent flow that unavoidably occurs asthe emulsion passes through the elbows, thus detracting from theefficiency of the separation process. Furthermore, “U-tube” firetubestend to corrode at a high rate, and they do not transfer heat evenly tothe emulsion bath inside the separator vessel. In addition, flangedvessel heads of the type required for such prior art separators requirea large number of bolts, plus a consumable gasket; for these reasons,assembly and disassembly of these separators are time-consumingprocesses, with considerable care being required during assembly toensure a proper seal with the vessel.

BRIEF SUMMARY

The present disclosure teaches embodiments of a horizontal productionseparator that avoid or mitigate one or more the above-noted problemswith conventional firetube separators. In accordance with one particularembodiment of a separator in accordance with the present disclosure,emulsion is preheated by flowing through a generally helical piping coilclosely encircling a single-cylinder, dual-chamber firetube disposedinside a horizontal separator vessel, promoting initial separation ofthe emulsion by means of heat transfer and centrifugal flow. Resultantcentripetal force separates lighter gaseous and liquid particles towardthe inside of the helical coil, while heavier emulsion fractionscondense toward the outside of the helical coil. The secondary flowwithin the helical coil promotes less wear, increases emulsion retentiontime, and naturally drops pressure. The helical configuration of thepreheat coil and the use of a single-cylinder, dual-chamber firetuberesult in reduced wear in both the coil and the firetube because of theelimination of the abrupt changes in flow direction (and consequentincreases in flow velocities) that characterize prior art separators dueto their use of tight-radius piping bends.

The helical preheat coil serves as an initial phase of the emulsionseparation process. Preferably, the coil will surround the firetube withlittle or no separation therebetween, in order to optimize heat transferfrom the firetube to the coil by both radiant and conductive heating.Exhaust from the firetube is economized to reduce paraffin build-up in ahigh-pressure vertical scrubber associated with the separator vessel.

In preferred embodiments, the separator has “quick-removal” vessel headsat one or both ends of the separator vessel, for quicker and easierassembly and disassembly than for conventional bolt-on vessel heads. Thehelical coil and the single firetube are affixed to one of thequick-removal vessel heads, thus allowing for quick and easy removal ofthese components for inspection and cleaning.

In one variant embodiment in accordance with the present disclosure, thesubassembly of the helical coil, the firetube, and the quick-removalvessel head can be adapted for retrofitting into a conventionalhorizontal separator, replacing the original straight-run emulsiontubing, U-shaped firetube, and bolt-on vessel head.

Accordingly, in a first aspect the present disclosure teaches aseparator assembly comprising:

-   -   a separator vessel having an interior chamber, a first end, and        a first removable vessel head associated with said first end of        the separator vessel;    -   a firetube disposed within the interior chamber of the separator        vessel;    -   a burner associated with a first end of the firetube; and    -   one or more helical coils for receiving a flow of emulsion, said        one or more emulsion coils being disposed around the firetube.

In one embodiment, the firetube may be a single-cylinder firetube havinga lower firetube chamber and an upper firetube chamber, with the one ormore helical coils being of generally circular configuration as seen inend view.

In alternative embodiments, the firetube may be a U-shaped firetube,with the one or more helical coils being either of generally circularconfiguration as seen in end view, or of generally ellipticalconfiguration as seen in end view.

The one or more helical coils, the firetube, and the first vessel headmay be arranged so as to form a subassembly that is removable from theinterior chamber of the separator vessel. Optionally, the subassemblymay include the burner.

Optionally, the first removable vessel head may be a quick-removalvessel head.

The separator vessel may be oriented horizontally, but this is notessential. Depending on the operational requirements and constraints ofa given installation, the separator vessel could have a non-horizontalorientation (e.g., vertical).

In a second aspect, the present disclosure teaches a separator assemblycomprising:

-   -   a separator vessel having an interior chamber, a first end, and        a first removable vessel head associated with said first end of        the separator vessel;    -   a firetube disposed within the interior chamber of the separator        vessel;    -   a burner associated with a first end of the firetube; and    -   one or more helical coils for receiving a flow of emulsion, said        one or more helical coils being disposed below the firetube.

The firetube below which the one or more helical coils are disposed maybe either a single-cylinder firetube or a U-shaped fire tube. The one ormore helical coils may be of generally elliptical configuration, andoptionally may be contoured for conformation with the shape of thefiretube.

Separators in accordance with the present disclosure can be configuredin sizes and orientations similar to existing separator designs, withchanges to internal retention and economizing the exhaust to achieveoptimal heat transfer. Initial emulsion flow is routed through helicalcoils that wrap around the single cylindrical fire tube. The tightarrangement of coils, that completely wrapping around the fire tube,conducts and radiates heat through to the fluid, heating it to allowpressure reduction from the wellhead into the vertical gas scrubber.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments in accordance with the present disclosure will now bedescribed with reference to the accompanying Figures, in which numericalreferences denote like parts, and in which:

FIG. 1 illustrates the vessel head, emulsion piping assembly, andU-shaped firetube of a prior art “180-10-pass” separator, shownextracted from one end of the separator vessel.

FIG. 2 is an exploded view of a first embodiment of a separator inaccordance with the present disclosure, with helical emulsion pipingcoils disposed around a single-cylinder, dual-chamber firetube, andhaving quick-removal vessel heads.

FIG. 3 is an oblique longitudinal cross-section through the separatorshown in FIG. 2.

FIG. 4 is side view of the separator shown in FIG. 2.

FIG. 4A is a partially-exploded version of FIG. 4, illustrating removalof the vessel head at one end of the separator vessel, and removal ofthe vessel head/firetube/emulsion piping subassembly from the other endof the separator vessel.

FIG. 5 is an isometric view of an exemplary embodiment of a helicalemulsion piping coil in accordance with the present disclosure.

FIG. 6 is an exploded view of a second embodiment of a separator inaccordance with the present disclosure, with “flattened” helicalemulsion piping coils configured to closely surround a conventionalU-shaped firetube.

FIG. 7 is an isometric view of the separator in FIG. 6, fully assembled.

FIG. 8 is an isometric view of an alternative embodiment of a vesselhead/firetube/emulsion piping subassembly in accordance with the presentdisclosure, with a quick-removal head carrying a conventional U-shapedfiretube surrounded by a helical emulsion piping coil.

DESCRIPTION

The construction and operation of separator embodiments in accordancewith the present disclosure will be readily apparent to persons ofordinary skill in the art, having regard to the accompanying Figures.

Having reference to the embodiment illustrated in FIGS. 2-4, separator100 includes a horizontal separator vessel 110 having an interiorchamber 112, a helical primary emulsion preheat coil 120, and a helicalsecondary emulsion preheat coil 130, with helical emulsion coils 120 and130 being coaxially disposed around a dual-chamber, single-cylinderfiretube 140 having a lower firetube chamber 142 and an upper firetubechamber 144. A burner 146 (typically gas-fired) is provided inassociation with the outer end of lower firetube chamber 142. A firstquick-removal vessel head 116 is provided at the burner end of vessel110, and a second quick-removal vessel head 114 is preferably providedat the other end of vessel 110.

During operation of separator 100, emulsion from a wellhead entersprimary preheat coil 120 via a preheat inlet 122 and flows to a choke(not shown) that reduces the pressure in primary preheat coil 120 to apredetermined level. This completes the first phase of the emulsionheating process. The emulsion then exits the choke and enters secondarypreheat coil 130 for the second heating phase.

After the emulsion has gone through the second heating phase, it entersa control valve (not shown) which controls emulsion flow to separatorvessel 110. The emulsion will then enter a vertical high-pressure bottle160 located above an economized exhaust 150 that extends from upperfiretube chamber 144 and runs horizontally above vessel 110. Theemulsion will then start to separate by means of pressure and gravity inhigh-phase bottle 160. Comingled emulsion will then dump into theemulsion bath inside interior chamber 112 of vessel 110 where emulsioncoils 120 and 130 and firetube 140 are located, in order to maintain aconstant separation temperature. Primarily, water and oil will then beseparated out of the emulsion. Secondarily, gas will be separated fromthe low-pressure horizontal unit. Emulsion coils 120 and 130 andfiretube 140 are carried by quick-removal vessel head 116, which issealingly connected to vessel 110.

Advantages of separators as exemplified by the embodiment shown in FIGS.2-4, relative to prior art separators such as the 180-10-pass design,include the following:

-   -   Emulsion flows from the wellhead into the helical coils starting        immediate separation due to centrifugal force and high heat        transfer.    -   Secondary fluid flow through the helical coils reduces pressure        naturally and promotes better emulsion separation with minimal        internal coil wear, whereas straight-run emulsion piping as in        prior art separators is prone to high internal wear, especially        at small-radius elbows.    -   The dual-chamber, single-cylinder firetube transfers and        maintains heat better and more efficiently than prior art        U-shaped firetubes, while having a smaller volumetric footprint        (i.e., the emulsion coils and firetube of the separator in FIGS.        2-4, in combination, take up less volume inside the vessel than        the emulsion piping and firetube of the prior art separator).    -   The helical coils wrapped around the single-cylinder firetube        are heated through both conductive and radiant heating.    -   The firetube and helical coil configuration maintains high        emulsion retention with a small volumetric footprint inside the        separator vessel.    -   Compared to conventional separators of similar size, higher        efficiency and higher emulsion throughput are achievable due to        the smaller volumetric footprint of the internal components        (i.e., single-cylinder firetube and helical coils).    -   Exhaust economizer routing exhaust through the vertical scrubber        (i.e., high-pressure bottle) and building can be used to heat        low-temperature areas.    -   Exhaust from the burner is routed through the vertical scrubber        to reduce paraffin buildup.    -   Exhaust from the burner may also be routed to heat the separator        control building and thereby reduce or prevent freezing on sight        glasses and valves in the building.    -   Quick-removal vessel head allows for quick access to the        separator vessel for inspection and cleaning.    -   Metal sealing surfaces on the quick-removal vessel heads        facilitate provision of a safe and efficient seal between the        vessel and vessel heads.

Referring now to FIGS. 6-7, a horizontal separator 200 in accordancewith an alternative embodiment has a separator vessel 210 having aninterior chamber 212 mounted above an insulated burner enclosure 245which has an interior chamber 247 housing generally elliptical (or“flattened”) helical emulsion coils 220 and 230 wrapped around aU-shaped firetube 240 (with associated burner 242 and exhaust 250).During operation of separator 200, emulsion is preheated by flowingthrough emulsion coils 220 and 230, before flowing into interior chamber212 of vessel 210 for further separation. Advantages of this design(over and above previously-noted advantages resulting from the use ofhelical emulsion coils instead of straight-run piping with small-radiuselbows) include the fact that the firetube and emulsion piping areoutside of vessel 210, which allows vessel 210 to have a smaller volumefor a given emulsion throughput. At the same time, sufficient heat canbe transferred to vessel 210 to keep paraffins in the emulsionliquefied.

FIG. 8 illustrates a subassembly comprising a quick-removal vessel head312 and a helical emulsion coil 320 in accordance with the presentdisclosure, in combination with a prior art U-shaped firetube 340. Thissubassembly can be used to retrofit prior art separators (such as butnot limited to the separator shown in FIG. 1) to obtain the operationalbenefits of helical emulsion coils over straight-run emulsion piping, aswell as the quick-removal vessel head, without needing to replace theexisting firetube burner.

It will be readily appreciated by those skilled in the art that variousmodifications to embodiments in accordance with the present disclosuremay be devised without departing from the scope of the presentteachings, including modifications which may use equivalent structuresor materials hereafter conceived or developed. It is to be especiallyunderstood that the scope of the present disclosure is not intended tobe limited to described or illustrated embodiments, and that thesubstitution of a variant of a claimed or illustrated element orfeature, without any substantial resultant change in functionality, willnot constitute a departure from the scope of the disclosure.

Athough the specific embodiments described and illustrated herein relateto horizontally-oriented, high-pressure separators, this is by way ofnon-limiting example only. Persons of ordinary skill in the art willappreciate that principles and concepts associated with the specificembodiments disclosed herein may also be adapted and applied toseparators of different physical configurations (such as but not limitedto vertically-oriented separators) without departing from the scope ofthe present disclosure, and that the practical applicability of suchprinciples and concepts is not limited to or restricted by anyparticular range of operating pressures.

In this patent document, any form of the word “comprise” is to beunderstood in its non-limiting sense to mean that any element or featurefollowing such word is included, but elements or features notspecifically mentioned are not excluded. A reference to an element bythe indefinite article “a” does not exclude the possibility that morethan one such element is present, unless the context clearly requiresthat there be one and only one such element. Any use of any form of theterms “connect”, “engage”, “couple”, “attach”, or any other termdescribing an interaction between elements is not meant to limit theinteraction to direct interaction between the subject elements, and mayalso include indirect interaction between the elements such as throughsecondary or intermediary structure.

Relational terms such as (but not limited to) “vertical”, “horizontal”,“parallel”, “elliptical”, and “coaxial” are not intended to denote orrequire absolute mathematical or geometrical precision. Accordingly,such terms are to be understood as denoting or requiring substantialprecision only (e.g., “substantially parallel” or “substantiallycoaxial”) unless the context clearly requires otherwise. Wherever usedin this document, the terms “typical” and “typically” are to beinterpreted in the sense of representative of common usage or practice,and are not to be understood as implying essentiality or invariability.

What is claimed is:
 1. A separator assembly comprising: (a) a separator vessel having an interior chamber, a first end, and a first removable vessel head associated with said first end of the separator vessel; (b) a firetube disposed within the interior chamber of the separator vessel; (c) a burner associated with a first end of the firetube; and (d) one or more helical coils for receiving a flow of emulsion, said one or more helical coils being disposed around the firetube.
 2. A separator assembly as in claim 1 wherein the firetube is a single-cylinder firetube having a lower firetube chamber and an upper firetube chamber.
 3. A separator assembly as in claim 1 wherein the one or more helical coils are of generally circular configuration as seen in end view.
 4. A separator assembly as in claim 1 wherein the firetube is a U-shaped firetube.
 5. A separator assembly as in claim 4 wherein the one or more helical coils are of generally circular configuration as seen in end view.
 6. A separator assembly as in claim 4 wherein the one or more helical coils are of generally elliptical configuration as seen in end view.
 7. A separator assembly as in claim 1 wherein the one or more helical coils, the firetube, and the first vessel head form a subassembly that is removable from the interior chamber of the separator vessel.
 8. A separator assembly as in claim 7 wherein the subassembly further includes the burner.
 9. A separator assembly as in claim 1 wherein the first removable vessel head is a quick-removal vessel head.
 10. A separator assembly as in claim 1 wherein the separator vessel is oriented horizontally.
 11. A separator assembly comprising: (a) a separator vessel having an interior chamber, a first end, and a first removable vessel head associated with said first end of the separator vessel; (b) a firetube disposed within the interior chamber of the separator vessel; (c) a burner associated with a first end of the firetube; and (d) one or more helical coils for receiving a flow of emulsion, said one or more helical coils being disposed below the firetube.
 12. A separator assembly as in claim 11 wherein the one or more helical coils are of generally elliptical configuration.
 13. A separator assembly as in claim 12 wherein the one or more helical coils are contoured for conformation with the shape of the firetube.
 14. A separator assembly as in claim 11 wherein the one or more helical coils, the firetube, and the first vessel head form a subassembly that is removable from the interior chamber of the separator vessel.
 15. A separator assembly as in claim 14 wherein the subassembly further includes the burner.
 16. A separator assembly as in claim 11 wherein the first removable vessel head is a quick-removal vessel head.
 17. A separator assembly as in claim 11 wherein the separator vessel is oriented horizontally. 